Composite building panels

ABSTRACT

A composite, insulated, structural panel, that includes an exterior face comprising a length and a width, an opposing interior face comprising the length and the width, a foam core disposed between the exterior face and the interior face, and a first plurality of reinforcement ribs attached to the interior face and extending laterally along the width, and extending outwardly into the foam core.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/187,057 filed on Jun. 30, 2015, the entire contentsof which are hereby incorporated by reference herein, for all purposes.

FIELD OF THE INVENTION

This invention relates to a composite building panel.

BACKGROUND OF THE INVENTION

Composite building materials have been used in construction industriesfor more than 50 years. The composite materials can be used to constructfloors, walls, and ceilings in buildings. To have a composite buildingpanel that can meet versatile needs, such as durability, low weight,impact resistance, design flexibility, high strength to weight ratio,heat resistance and insulation, sound damping and other insulationproperties, weight bearing, etc, is desirable.

Prior art composite, insulated, structural panels typically utilizemetal parts, such as wall fasteners, structural ribs, stand-offs, andthe like, that extend through the thickness of the panel. Those metalparts effectively comprise thermal conduction pathways from the outersurface of the panel to the inner surface of the panel. Such thermalconduction pathways render those prior art panels very inefficient withrespect to maintaining an interior building temperature.

SUMMARY OF THE INVENTION

A composite, insulated, structural panel, is disclosed. The composite,insulated, structural panel includes an exterior face comprising alength and a width, an opposing interior face comprising the length andthe width, a foam core disposed between the exterior face and theinterior face, and a first plurality of reinforcement ribs attached tothe interior face and extending laterally along the width, and extendingoutwardly into the foam core, wherein in certain embodiments the firstplurality of reinforcement ribs are formed from one or more metals. Inthese embodiments, however, none of the first plurality of reinforcementribs extends from the interior face to the exterior face, therebyeliminating the metal thermal conduction pathways found in prior artcomposite panels.

A composite structural beam is disclosed. The composite structural beamincludes a pair of interleaved brackets, and a foam core disposedbetween the pair of interleaved brackets.

A composite jamb stud is disclosed. The composite jamb stud includes apair of interleaved brackets, in combination with a foam core disposedbetween the pair of interleaved brackets.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood from a reading of the followingdetailed description taken in conjunction with the drawings in whichlike reference designators are used to designate like elements, and inwhich:

FIG. 1 illustrates an isometric view of one embodiment of Applicants'composite panels 100;

FIG. 2 is a sectional view of the embodiment of Applicants' compositepanels 100 illustrated in FIG. 1;

FIG. 3 illustrates a sectional view of one embodiment of a firstcomposite panel 100A attaching to a second composite panel 100B;

FIG. 4 illustrates a sectional view of another embodiment of a firstcomposite panel 100A attaching to a second composite panel 100B;

FIG. 5 illustrates an isometric view of another embodiment ofApplicants' composite panels 500;

FIG. 6 is a sectional view of the embodiment of Applicants' compositepanels 500 illustrated in FIG. 5;

FIG. 7 is a sectional view of one embodiment of a first composite panel500A attaching to a second composite panel 500B;

FIG. 8 shows an isometric view of another embodiment of Applicants'composite panels 800;

FIG. 9A is a sectional view of the embodiment of Applicants' compositepanels 800 illustrated in FIG. 8;

FIG. 9B is a sectional view of the embodiment of Applicants' compositepanels 800 illustrated in FIG. 8 with a different embodiment of areinforcement rib;

FIG. 9C is a sectional view of the embodiment of Applicants' compositepanels 800 illustrated in FIG. 8 with another embodiment of areinforcement rib;

FIG. 10A is a sectional view of one embodiment of a first compositepanel 800A attaching to a second composite panel 800B;

FIG. 10B is a sectional view of another embodiment of a first compositepanel 800A attaching to a second composite panel 800B;

FIG. 11 shows an isometric view of another embodiment of Applicants'composite panels 1100;

FIG. 12 is a sectional view of the embodiment of Applicants' compositepanels 1100 illustrated in FIG. 11;

FIG. 13 is a sectional view of one embodiment of a first composite panel1100A attaching to a second composite panel 1100B;

FIG. 14 shows an isometric view of another embodiment of Applicants'composite panels 1400;

FIG. 15 is a sectional view of the embodiment of Applicants' compositepanels 1400 illustrated in FIG. 14;

FIG. 16 is a sectional view of one embodiment of a first composite panel1400A attaching to a second composite panel 1400B;

FIGS. 17A and 17B show an isometric view of one embodiment of a jambstud and a section view of the jamb stud;

FIGS. 18A and 18B illustrate an isometric view of another embodiment ofa jamb stud and a sectional view of the jamb stud illustrated;

FIG. 19 shows an isometric view of an embodiment of a header beam;

FIG. 20 illustrates an isometric view of an assembly of the jamb studillustrated in FIG. 17A and the header beam illustrated in FIG. 19; and

FIG. 21 is an isometric view of one embodiment of Applicants' compositebeam.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention is described in preferred embodiments in the followingdescription with reference to the Figures, in which like numbersrepresent the same or similar elements. Reference throughout thisspecification to “one embodiment,” “an embodiment,” or similar languagemeans that a particular feature, structure, or characteristic describedin connection with the embodiment is included in at least one embodimentof the present invention. Thus, appearances of the phrases “in oneembodiment,” “in an embodiment,” and similar language throughout thisspecification may, but do not necessarily, all refer to the sameembodiment.

The described features, structures, or characteristics of the inventionmay be combined in any suitable manner in one or more embodiments. Inthe following description, numerous specific details are recited toprovide a thorough understanding of embodiments of the invention. Oneskilled in the relevant art will recognize, however, that the inventionmay be practiced without one or more of the specific details, or withother methods, components, materials, and so forth. In other instances,well-known structures, materials, or operations are not shown ordescribed in detail to avoid obscuring aspects of the invention.

In certain embodiments, Applicant's composite insulated structural panelcomprises one or more materials on an exterior face, an integrated foamcore and one or more structural ribs on an interior face, with someembodiments having structural ribs on an exterior face also.

In certain embodiments, both the interior ribs and the exterior faceribs (when used), can be made from a variety of materials, including butnot limited to light gage steel or a fiber reinforced polymer material(fiberglass, carbon fiber, plastic). The ribs can be formed to variousprofiles, and are integrally bonded to the foam core. In certainembodiments, the ribs provide structural strength and stiffness forApplicant's composite panel, and the size, thickness, material andspacing of these ribs would vary depending on the span and loadingrequirements for a specific application.

The interior ribs are positioned to extend outwardly from anunclad/unsheathed foam surface of the panel, providing a stand-offspace. This stand-off space accommodates the installation of utilities(electrical wiring and small water lines) to be installed after thepanels have been erected when used in a building application. Holesthrough the ribs can be pre-drilled prior to panel manufacturing, orfield drilled to allow the utilities to continue perpendicular to theribs. An interior finish such as gypsum board (drywall), wood paneling,etc. can be installed by attaching directly to the interior ribs, if afinished surface is desired.

Applicant's composite panels are formed such that interior ribs are notin direct contact with the exterior surface of the panel, therebyeliminating a thermal link between the exterior face and the interiorface of the panel. This provides an advantage for energy efficientbuilding design.

In certain embodiments, the foam core can be manufactured from variousmaterials, and with different thicknesses, depending on project needsand the amount of insulation value desired.

Thermal insulation is the reduction of heat transfer (the transfer ofthermal energy between objects of differing temperature) between objectsin thermal contact or in range of radiative influence. Thermalinsulation can be achieved with specially engineered methods orprocesses, as well as with suitable object shapes and materials.

Heat flow is an inevitable consequence of contact between objects ofdiffering temperature. Thermal insulation provides a region ofinsulation in which thermal conduction is reduced or thermal radiationis reflected rather than absorbed by the lower-temperature body.

The insulating capability of a material is measured with thermalconductivity (k). Low thermal conductivity is equivalent to highinsulating capability (R-value). In thermal engineering, other importantproperties of insulating materials are product density (ρ) and specificheat capacity (c).

In certain embodiments, Applicant's foam core used in composite panels100, 500, 800, and 1100, comprises a polyurethane foam formed in situusing a spray foam technique. Polyurethane was developed and used by themilitary in the 1940s and applied to airplanes. It wasn't until the1970s that it started to be used as foam insulation.

In certain embodiments, Applicant's foam core comprises a closed cellfoam. In certain embodiments, Applicant's spray foam system utilizes achlorofluorocarbon blowing agent in a closed cell system.

Applicant utilizes various systems to apply the spray foam. In certainembodiments, Applicant utilizes a two component low pressure spray foamsystem. This is also known as a slow rise formula and often referred toas injection foam.

In certain embodiments, Applicant's foam core used in composite panels100, 500, 800, and 1100, comprises a closed cell, polyisocyanurate foamformed in situ using a spray foam technique. The reaction of MDI andpolyol takes place at higher temperatures compared with the reactiontemperature for the manufacture of polyurethane foam.

At these elevated temperatures and in the presence of specificcatalysts, a diisocyanate methylene diisocyanate (“MDI”) will firstreact with itself, producing a stiff, ring molecule, which is a reactiveintermediate (a tri-isocyanate isocyanurate compound). Remaining MDI andthe tri-isocyanate react with polyol to form a complexpoly(urethane-isocyanurate) polymer, which is foamed in the presence ofa suitable blowing agent.

This isocyanurate polymer has a relatively strong molecular structure,because of the combination of strong chemical bonds, the ring structureof isocyanurate and high cross link density, each contributing to thegreater stiffness than found in comparable polyurethanes. The greaterbond strength also means these are more difficult to break, and as aresult a PIR foam is chemically and thermally more stable: breakdown ofisocyanurate bonds is reported to start above 200° C., compared withurethane at 100 to 110° C.

Applicant's polyisocyanurate foam systems typically comprises anMDI/polyol ratio, also called its index (based on isocyanate/polyolstoichiometry to produce urethane alone), higher than 180. By comparisonpolyurethane indices are normally around 100. As the index increasesmaterial stiffness also increases.

In certain embodiments, greater stiffness, chemical and/or thermalstability are desirable in Applicant's composite panels 100 (FIG. 1),500 (FIG. 5), 800 (FIG. 8), 1100 (FIG. 11), and 1400 (FIG. 14). Incertain embodiments, the foam core 120 portion in Applicant's compositepanels 100 (FIG. 1), 500 (FIG. 5), 800 (FIG. 8), 1100 (FIG. 11), and1400 (FIG. 14) comprises a closed cell, polyisocyanurate foam.

The panels, when used in a building application, can be used for roofs,floors and walls. The wall panels can be designed as load-bearing, ornon-load bearing.

Applicant's composite panels are formed such that interior ribs are notin direct contact with the exterior surface of the panel, therebyeliminating a thermal link between the exterior face and the interiorface of the panel. This provides an advantage for energy efficientbuilding design.

Applicant's composite panel design is efficient, taking advantage of afoam core as both insulation and a structural core material. Typicalfiberglass batt insulation currently used in most buildings provides nostructural value.

In a building application, the panels eliminate sub-framing (trusses,joists, purlins, girts, etc.) currently used with traditionalconstruction. This will reduce construction material costs and laborcosts by eliminating numerous pieces and speed up the constructionprocess.

The typical connections of the panels to the supporting structure (orpanel to panel connections) could be made on the interior of thestructure, thus eliminating any possible water intrusion from screwholes on the exterior that extend through the panel, like that currentlyused for sandwich panels and SIPS panels. Moreover, the foam coreprovides better acoustics/sound control over typical construction usingfiberglass batt insulation.

A first embodiment of Applicant's composite panel can be utilized asboth a roof and wall panel. In certain embodiments, this firstembodiment of Applicant's composite panel comprises an outer facing, butno inner facing. Referring now to FIG. 1, Applicant's composite panel100 comprises an outerfacing 110 disposed over a foam core 120 withintegral interior ribs creating a composite structural panel. Compositepanel 100 comprises no inner facing. As those skilled in the art willappreciate, by “outer facing” Applicant means a surface of the compositepanel intended for exterior use. By “inner facing,” Applicant means asurface of the composite panel not intended for exterior use.

Referring now to FIGS. 1, 2, 3, and 4, an exterior facing 110 comprisesa metal deck profile or gage, including a standing seam deck common inthe metal building industry. The target market and advantages would be:a) pre-engineered metal buildings; eliminating the roof purlins and wallgirts, along with batt insulation currently used, and Type A panelswould span directly to the buildings main frames; or b) any buildingwhere a metal panel exterior finish is desired.

In the illustrated embodiment of FIGS. 1 and 2, Applicant's compositepanel 100 comprises a reinforcing rib in the form of channel 140extending the entire length 102 of panel 100. Channel 140 comprises apair of sides 141 and 144, wherein proximal portions 142 and 145 ofsides 141 and 144, respectively, are disposed/molded within foam core120. In certain embodiments, wherein those proximal portions 142 and 145are formed to include textured surfaces for enhanced mechanical adhesionto form core 120. Distal portions 143 and 146 of sides 141 and 144,respectively, extend outwardly from surface 104 of foam core 120.

Referring again to FIG. 1, element 140 comprises a “U-shaped” channelthat extends the entire length 102 of panel 100, and functions as areinforcing rib for composite panel 100. Referring again to FIG. 2,floor 149 of the “U-shaped” channel 140 can be used as a stand-off rib.Stand-off ribs 130, 148, 158, 160, can be used to receive gypsum board,wood paneling, stucco, siding, veneer, and the like 149, by screws,nails or adhesive to the bottom surface of the ribs.

FIG. 1 illustrates reinforcing rib 140 as a “U-shaped” channel. Thisdepiction should not be taken as limiting. In other embodiments,Applicant's reinforcing ribs can be formed from wood, metal, ceramicmaterials, and combinations thereof.

None of the reinforcing ribs 140 extend to, or outwardly from,metal/plastic surface 110. This being the case, none of the reinforcingribs 140 can function as a thermal conduit transferring heat, in eitherdirection, from surface 110 (FIGS. 1, 2) to surface 104 (FIG. 2), orvice versa.

Further illustrated embodiment of FIGS. 1 and 2, Applicant's compositepanel 100 comprises a “U-shaped” channel 150 extending the entire length102 of panel 100. Reinforcing rib 150 comprises a pair of sides 151 and154, wherein proximal portions 152 and 155 of sides 151 and 154,respectively, are disposed/molded within foam core 120. Distal portions153 and 156 of sides 151 and 154, respectively, extend outwardly fromsurface 104 of foam core 120.

As shown in FIG. 1, distal portions 153 and 156 of legs 151 and 154,respectively, are formed to include an aperture extending therethrough.As further shown in FIGS. 1 and 2, electrical cabling and/or piping 159can be routed through the apertures formed in legs 151 and 154.

FIGS. 1 and 2 show a single cable/pipe 159 extending through channel150. FIGS. 1 and 2 should not be taken as limiting. In certainembodiments, reinforcing rib 150 is formed to include a plurality ofaperture pairs formed therein along the length 102 of Applicant'scomposite panel 100.

Reinforcing rib 150 functions as a reinforcing rib for composite panel100. In addition, as described herein above reinforcing rib 150 can alsobe used to fixture electrical cables, piping, and the like, to surface104 of composite panel 100.

None of the reinforcing ribs 150 extend to, or outwardly from,metal/plastic surface 110. This being the case, none of the reinforcingribs 150 can function as a thermal conduit transferring heat, in eitherdirection, from surface 110 to surface 104, or vice versa.

As shown in FIG. 1, Applicant's composite panel 100 comprises a firstpanel connecting channel 130 disposed on a first side of composite panel100 and extending throughout length 102 of panel 100. Applicant'scomposite panel 100 further comprises a second panel connecting channel160 disposed on a second and opposing side of composite panel 100 andextending throughout width 102 of panel 100.

In the illustrated embodiment of FIG. 3, a first composite panel 100A isshown attached to a second composite panel 100B. A second attachmentchannel 160 of composite panel 100A is disposed against a firstattachment channel 130 of composite panel 100B.

An attachment means 310 is shown interconnecting attachment channel 160to attachment channel 130. The illustrated embodiment of FIG. 3 shows asingle attachment means 310. FIG. 3 should not be taken as limiting. Incertain embodiments, a plurality of attachment means 310 interconnectattachment channel 160 of composite panel 100A to attachment channel 130of composite panel 100B.

FIG. 4 shows a first panel 100A attached to a second panel 100B as shownin FIG. 3. In addition, metal surface 110A and metal surface 110B arefastened together using a rolled seam 410.

Referring now to FIGS. 5, 6, and 7, Applicant's composite panel 500comprises a foam core 120 in combination with a top sheathing layer 510.In certain embodiments, the foam core 120 is formed as an integralassembly with top sheathing layer 510 using a spray foam system. Inother embodiments, foam core 120 is mechanically attached to topsheathing layer 510 using various attachment means including roofingnails, screws, and the like. In still other embodiments, foam core 120is attached to top sheathing layer 510 using one or more adhesives.

Composite panel 500 further comprises one or more “U-shaped” channels140 integrally molded into the foam core 120, and extending the entirelength 502 of composite panel 500. Reinforcing rib 140 functions as areinforcing rib for composite panel 500. In addition, as describedherein above reinforcing rib 140 can also be used as a stand-off rib forattachment of various traditional surface materials, including withoutlimitation gypsum board, stucco, siding, veneer, and the like.

As described hereinabove, reinforcing ribs 140 extend outwardly fromsurface 504. None of the reinforcing ribs 140 extend to, or outwardlyfrom, sheathing 510. This being the case, none of the reinforcing ribs140 can function as a thermal conduit transferring heat, in eitherdirection, from surface 502 to surface 504, or vice versa.

Composite panel 500 further comprises one or more “U-shaped” channels150 integrally molded into the foam core 120, and extending the entirelength 502 of composite panel 500. Reinforcing rib 150 functions as areinforcing rib for composite panel 500. In addition, as describedherein above reinforcing rib 150 can also be used to fixture electricalcables, piping, and the like, to the “interior surface,” i.e. thenon-sheathing side, of composite panel 500.

As described hereinabove, reinforcing ribs 150 extend outwardly fromsurface 504. None of the reinforcing ribs 150 extend to, or outwardlyfrom, sheathing 510. This being the case, none of the reinforcing ribs150 can function as a thermal conduit transferring heat, in eitherdirection, from surface 502 to surface 504, or vice versa.

In the illustrated embodiment of FIG. 6, Applicant's composite panel 500comprises reinforcing ribs 520A, 520B, and 520C, integrally molded intofoam core 120, and extending the entire length 502 of composite panel500. None of the reinforcing ribs 520A, 520B, and 520C, extend to, oroutwardly from, surface 504 (FIG. 6). This being the case, none of thereinforcing ribs 520A, 520B, and 520C, can function as a thermal conduittransferring heat, in either direction, from surface 502 (FIG. 6) tosurface 504 (FIG. 6), or vice versa.

In the illustrated embodiment of FIG. 7, a first composite panel 500A isshown attached to a second composite panel 500B. A second attachmentchannel 160 of composite panel 500A is disposed adjacent a firstattachment channel 130 of composite panel 500B.

An attachment means 310 is shown interconnecting attachment channel 160to attachment channel 130. The illustrated embodiment of FIG. 7 shows asingle attachment means 310. FIG. 7 should not be taken as limiting. Incertain embodiments, a plurality of attachment means 310 interconnectattachment channel 160 of composite panel 500A to attachment channel 130of composite panel 500B.

Referring now to FIG. 8, Applicant's composite panel 800 comprises afoam core 120 in combination with one or more “U-shaped” channels 140A(FIG. 9A), “C-shaped” channels 140B (FIG. 9B), or “Z-shaped” channels140C (FIG. 9C), integrally molded into the foam core 120, and extendingthe entire length 802 of composite panel 800. Applicant's composite foampanel 800 further comprises one or more “U-shaped” channels 150integrally molded into the foam core 120, and extending the entirelength 802 of composite panel 800. Applicant's composite panel 800comprises no metal/plastic surface 110, and no sheathing layer 510.Rather, material covering surface 902 (FIG. 9A) of Applicant's compositepanel 800 is “field installed.”

Reinforcing rib 140 functions as a reinforcing rib for composite panel800. In addition, as described herein above reinforcing rib 140 can alsobe used as a stand-off rib for attachment of various traditional surfacematerials, including without limitation, stucco, siding, veneer, and thelike.

As described hereinabove, reinforcing ribs 140A (FIG. 9A), 140B (FIG.9B), and 140C (FIG. 9C) extend outwardly from surface 904. None of thereinforcing ribs 140A-140C extend to, or outwardly from, top foamsurface 902 (FIGS. 9A-9C). This being the case, none of the reinforcingribs 140A-140C can function as a thermal conduit transferring heat, ineither direction, from surface 902 to surface 904, or vice versa.

Composite panel 800 further comprises one or more “U-shaped” channels150 integrally molded into the foam core 120. Reinforcing rib 150functions as a reinforcing rib for composite panel 800. In addition, asdescribed herein above reinforcing rib 150 can also be used to fixtureelectrical cables, piping, and the like, to the “interior surface,” i.e.the non-sheathing side, of composite panel 500.

As described hereinabove, reinforcing ribs 150 extend outwardly fromsurface 904. None of the reinforcing ribs 150 extend to, or outwardlyfrom, surface 902. This being the case, none of the reinforcing ribs 150can function as a thermal conduit transferring heat, in eitherdirection, from surface 902 to surface 904, or vice versa.

In the illustrated embodiment of FIGS. 8 and 9A-9C, Applicant'scomposite panel 800 comprises reinforcing ribs 520A, 520B, and 520C,integrally molded into foam core 120 (FIGS. 9A and 9B). In someembodiments, Applicant's composite panel 800 comprises “Z-shaped”reinforcing ribs 522A, 522B, and 522C (FIG. 9C). None of the reinforcingribs 520A, 520B, and 520C, extend to, or outwardly from, surface 902(FIGS. 9A and 9B). None of the reinforcing ribs 522A, 522B, and 522C,extend to, or outwardly from, surface 902 (FIG. 9C). This being thecase, none of the reinforcing ribs 520A, 520B, 520C, 522A, 522B, and522C can function as a thermal conduit transferring heat, in eitherdirection, from surface 902 to surface 904, or vice versa.

In the illustrated embodiment of FIG. 10A, a first composite panel 800Ais shown attached to a second composite panel 800B. A second attachmentchannel 160 of composite panel 800A is disposed adjacent a firstattachment channel 130 of composite panel 800B.

In the illustrated embodiment of FIG. 10B, a first composite panel 800Ais shown attached to a second composite panel 800B. A “C-shaped” secondattachment channel 160B of composite panel 800A is disposed adjacent a“C-shaped” first attachment channel 130B of composite panel 800B.

An attachment means 310 is shown interconnecting attachment channel 160to attachment channel 130. The illustrated embodiment of FIG. 3 shows asingle attachment means 310. FIG. 3 should not be taken as limiting. Incertain embodiments, a plurality of attachment means 310 interconnectattachment channel 160 of composite panel 800A to attachment channel 130of composite panel 800B.

In certain embodiments, Applicant's composite panel 100 (FIGS. 1, 2, 3,4) can be used as a roof panel. In certain embodiments, composite panel100 can be designed and manufactured with a radius/curved roof if thatprofile is desired.

Applicant's composite panel 500 (FIGS. 5, 6, 7) can be used in virtuallyany building type. Composite panel 500 is a variation of the currentindustry SIPS panels, with the exception that composite panel 500 panelcomprises sheathing on the exterior face only, and comprises thestand-off ribs on the interior surface only.

For both Applicant's composite panel 100 and composite panel 500,various roofing materials (asphalt shingles, built-up roofing, tiles,etc.) can be installed. When used for walls, various traditional surfacematerials (stucco, siding, veneer, etc.) can be used.

Applicant's composite panel 800 is similar to the composite panel 500,except the exterior face sheathing is field installed after the panelsare erected. This provides flexibility in design and construction, and areduced shipping cost over the composite panel 500. In certainembodiments, Applicant's composite panel 800 can also be used forinterior wall or partitions, providing an increased acoustic value andpotential savings in construction time over conventional construction ofthese types of walls.

Applicant's composite panels 1100 (FIGS. 11, 12, 13) and 1400 (FIGS. 14,15, 16) are designed for roof applications where a traditional tile roofappearance is desired. These panels provide the advantage of lightweight, and will speed up construction by eliminating most if not all ofthe wood framing (trusses, etc.) used in current traditionalconstruction. Use of composite panels 1100 and 1400 also reduces thelabor of installing the roof tiles, and could virtually eliminate theroof leak potential that current installation procedures create (nailingthrough the roofing paper).

Referring now to FIGS. 11, 12, and 13, Applicant's composite panel 1100comprises a foam core 120 in combination with a top concrete layer 1110.In certain embodiments, the foam core 120 is formed as an integralassembly with top concrete layer 1110, using Applicant's spray foamsystem. In other embodiments, foam core 120 is mechanically attached toconcrete layer 1110 using various attachment means including nails,screws, and the like. In still other embodiments, foam core 120 isattached to concrete layer 1110 using one or more adhesives.

In the illustrated embodiments of FIGS. 11, 12, and 13, Applicant'scomposite panel 1100 further comprises a plurality of roof tiles 1120attached to the concrete layer 1110. In certain embodiments, theplurality of roof tiles 1120 are “field installed” after installation ofthe composite panels 1100.

Composite panel 1100 further comprises one or more “U-shaped” channels140 integrally molded into the foam core 120, and extend the entirelength 1102 of composite panel 1100. Reinforcing rib 140 functions as areinforcing rib for composite panel 1100. In addition, as describedherein above reinforcing rib 140 can also be used as a stand-off rib forattachment of various traditional surface materials, including withoutlimitation stucco, siding, veneer, and the like.

Reinforcing ribs 140 extend outwardly from surface 1204 (FIG. 12). Noneof the reinforcing ribs 140 extend to, or outwardly from, surface 1202.This being the case, none of the reinforcing ribs 140 can function as athermal conduit transferring heat, in either direction, from surface1202 to surface 1204, or vice versa.

Composite panel 1100 further comprises one or more “U-shaped” channels150 integrally molded into the foam core 120, and extend the entirelength 1102 of composite panel 1100. Reinforcing rib 150 functions as areinforcing rib for composite panel 1100. In addition, as describedherein above reinforcing rib 150 can also be used to fixture electricalcables, piping, and the like, to surface 1204 of composite panel 500.

Reinforcing ribs 150 extend outwardly from surface 1204. None of thereinforcing ribs 150 extend to, or outwardly from, surface 1202. Thisbeing the case, none of the reinforcing ribs 150 can function as athermal conduit transferring heat, in either direction, from surface1202 to surface 1204, or vice versa.

In the illustrated embodiment of FIG. 12, Applicant's composite panel1100 comprises reinforcing ribs 520A, 520B, and 520C, integrally moldedinto foam core 120, and extend the entire length 1102 of composite panel1100. None of the reinforcing ribs 520A, 520B, and 520C, extend to, oroutwardly from, surface 1204 (FIG. 12). This being the case, none of thereinforcing ribs 520A, 520B, and 520C, can function as a thermal conduittransferring heat, in either direction, from surface 1202 (FIG. 9) tosurface 1204 (FIG. 9), or vice versa.

Referring now to FIGS. 14, 15, and 16, Applicant's composite panel 1400comprises a foam core 120 in combination with a top concrete layer 1510,molded to appear like concrete roof tiles, slate shingles, wood shakeshingles, or any similar roofing material. In certain embodiments, thefoam core 120 is formed as an integral assembly with top concrete layer1510 using Applicant's spray foam system. In other embodiments, foamcore 120 is mechanically attached to concrete layer 1510 using variousattachment means including nails, screws, and the like. In still otherembodiments, foam core 120 is attached to concrete layer 1510 using oneor more adhesives.

In the illustrated embodiments of FIGS. 14, 15, and 16, Applicant'scomposite panel 1400 further comprises a plurality of slate tiles 1410attached to the concrete layer 1510. The basic concept for this panel isthat the concrete surface is molded to look like a shingle/slate/woodshake roof and that there is no field installing of those type ofmaterials. If field install shingles are preferable than the user coulduse panel 500 or 800. In certain embodiments, the plurality of slatetiles 1410 are “field installed” after installation of the compositepanels 1400.

Composite panel 1400 further comprises one or more “U-shaped” channels140 integrally molded into the foam core 120, and extend the entirelength 1402 of composite panel 1400. Reinforcing rib 140 functions as areinforcing rib for composite panel 1400. In addition, as describedherein above reinforcing rib 140 can also be used as a stand-off rib forattachment of various traditional surface materials, including withoutlimitation stucco, siding, veneer, and the like.

Reinforcing ribs 140 extend outwardly from surface 1504 (FIG. 15). Noneof the reinforcing ribs 140 extend to, or outwardly from, surface 1502.This being the case, none of the reinforcing ribs 140 can function as athermal conduit transferring heat, in either direction, from surface1502 to surface 1504, or vice versa.

Composite panel 1400 further comprises one or more “U-shaped” channels150 integrally molded into the foam core 120, and extending the entirelength 1402 of composite panel 1100. Reinforcing rib 150 functions as areinforcing rib for composite panel 1400. In addition, as describedherein above reinforcing rib 150 can also be used to fixture electricalcables, piping, and the like, to surface 1504 of composite panel 1400.

Reinforcing ribs 150 extend outwardly from surface 1504. None of thereinforcing ribs 150 extend to, or outwardly from, surface 1502. Thisbeing the case, none of the reinforcing ribs 150 can function as athermal conduit transferring heat, in either direction, from surface1502 to surface 1504, or vice versa.

In the illustrated embodiment of FIG. 15, Applicant's composite panel1400 comprises reinforcing ribs 520A, 520B, and 520C, integrally moldedinto foam core 12, and extending the entire length 1402 of compositepanel 1400. None of the reinforcing ribs 520A, 520B, and 520C, extendto, or outwardly from, surface 1504. This being the case, none of thereinforcing ribs 520A, 520B, and 520C, can function as a thermal conduittransferring heat, in either direction, from surface 1502 to surface1504, or vice versa.

Miscellaneous pieces such as jambs and headers at openings, corners,sills, headers and trimmers at roof openings, and the like are designed,detailed and provided as part of a complete system. All of Applicant'scomposite assemblies, including composite roof panels, composite wallpanels, and such miscellaneous assemblies, all implement the sameconcept: namely, no thermal link, accommodating utilities through thestand-off space, and providing ribs (flush or stand-off) for attachmentof other materials.

Referring now to FIGS. 17A and 17B, Applicant's jam stud 1700 comprisesinterlaced “L-shaped” studs 1710A and 1710B. As shown in FIG. 17A,interlaced L-shaped studs 1710A and 1710B define a substantiallyenclosed space. Foam core 120 is disposed within that substantiallyenclosed space.

In certain embodiments, the foam core 120 is formed as an integralassembly with interlaced L-shaped studs 1710A and 1710B usingApplicant's spray foam system. In other embodiments, foam core 120 ismechanically attached to interlaced L-shaped studs 1710A and 1710B usingvarious attachment means including nails, screws, and the like. In stillother embodiments, foam core 120 is attached to interlaced L-shapedstuds 1710A and 1710B using one or more adhesives.

Referring now to FIGS. 18A and 18B, Applicant's assembly 1800 comprisesjamb stud 1700 (FIGS. 17A, 17B) in combination with jack stud 1810. Jackstud 1810 comprises housing 1820 which defines two substantiallyenclosed spaces, namely substantially enclosed space 1822 andsubstantially enclosed space 1824.

Referring now to FIG. 19, Applicant's header beam 1900 comprisesinterlaced “U-shaped” brackets 1910A and 1910B to form a substantiallyenclosed space.

Foam core 120 is disposed within that substantially enclosed space. Incertain embodiments, the foam core 120 is formed the substantiallyenclosed space as an integral assembly with interleaved “U-shaped”brackets 1910A and 1910B using Applicant's spray foam system. In otherembodiments, foam core 120 is mechanically attached to interleaved“U-shaped” brackets 1910A and 1910B using various attachment meansincluding nails, screws, and the like. In still other embodiments, foamcore 120 is attached to interleaved “U-shaped” brackets 1910A and 1910Busing one or more adhesives.

Referring now to FIG. 21, Applicant's composite beam 2100 comprises afirst reinforcing rib 2110 disposed around a portion of foam core 120,in combination with a second reinforcing rib disposed within foam core120. In certain embodiments, both the first reinforcing rib and thesecond reinforcing rib extend the entire length 2102 of header 2100.

In certain embodiments, foam core 120, comprising an embeddedreinforcing rib 2120, is formed as an integral assembly with U-shapedbracket 2110. In other embodiments, foam core 120, comprising anembedded reinforcing rib 2120, is mechanically attached to U-shapedbacked 2110 using various attachment means including nails, screws, andthe like. In still other embodiments, foam core 120, comprising anembedded reinforcing rib 2120, is attached to U-shaped backed 2110 usingone or more adhesives.

In the illustrated embodiment of FIG. 20, Applicant's assembly 2000comprises jam stud 1700, in combination with jack stud 1800, and header1900. Further in the illustrated embodiment of FIG. 20, header 1900 isattached to jam stud 1700 using brackets 2010 and 2020. In analternative embodiment, Applicant's assembly 2000 comprises jamb stud1700, in combination with jack stud 1800, and header 2100.

While the preferred embodiments of the present invention have beenillustrated in detail, it should be apparent that modifications andadaptations to those embodiments may occur to one skilled in the artwithout departing from the scope of the present invention.

We claim:
 1. A composite, insulated, structural panel, comprising: anexterior face comprising a length and a width; an opposing interior facecomprising said length and said width; a foam core disposed between saidexterior face and said interior face; a first plurality of reinforcementribs attached to said interior face and extending laterally along saidwidth, and extending outwardly into said foam core.
 2. The composite,insulated, structural panel of claim 1, wherein: said first plurality ofreinforcement ribs are formed from one or more metals; none of saidfirst plurality of reinforcement ribs extends from said interior face tosaid exterior face.
 3. The composite, insulated, structural panel ofclaim 1, wherein said one or more first plurality of reinforcement ribscomprise a U-shape.
 4. The composite, insulated, structural panel ofclaim 1, wherein said one or more first plurality of reinforcement ribscomprise a C-shape.
 5. The composite, insulated, structural panel ofclaim 1, wherein said one or more first plurality of reinforcement ribscomprise a Z-shape.
 6. The composite, insulated, structural panel ofclaim 1, further comprising: a first stand-off rib disposed adjacent afirst end, and extending laterally along said width, wherein a portionof said first stand-off extends outwardly from said interior face; asecond stand-off rib disposed adjacent a second end, and extendinglaterally along said width, wherein a portion of said second stand-offextends outwardly from said interior face; wherein: a first composite,insulated, structural panel can be attached to a second composite,insulated, structural panel by attaching a first stand-off rib disposedin said first composite, insulated, structural panel to a secondstand-off rib disposed in said second composite, insulated, structuralpanel.
 7. The composite, insulated, structural panel of claim 1, furthercomprising: a second plurality of reinforcement ribs attached to saidexterior face and extending laterally along said width, and extendingoutwardly into said foam core.
 8. The composite, insulated, structuralpanel of claim 7, wherein: said second plurality of reinforcement ribsare formed from one or more metals; none of said second plurality ofreinforcement ribs extends from said exterior surface face to saidinterior face; and none of said first plurality of reinforcement ribscontacts any of said second plurality of reinforcement ribs.
 9. Thecomposite, insulated, structural panel of claim 7, wherein said one ormore second plurality of reinforcement ribs comprise a U-shape.
 10. Thecomposite, insulated, structural panel of claim 7, wherein said one ormore first plurality of reinforcement ribs comprise a C-shape.
 11. Thecomposite, insulated, structural panel of claim 7, wherein said one ormore first plurality of reinforcement ribs comprise a Z-shape.
 12. Thecomposite, insulated, structural panel of claim 1, wherein: a topsurface of said foam core comprises said exterior face; and an opposingbottom surface of said foam core comprises said interior face.
 13. Thecomposite, insulated, structural panel of claim 1, further comprising: asheathing material disposed over a top surface of said foam core;wherein said sheathing material comprises said exterior face.
 14. Thecomposite, insulated, structural panel of claim 13, wherein saidsheathing material comprises metal.
 15. The composite, insulated,structural panel of claim 13, wherein said sheathing material comprisesa plurality of clay tiles.
 16. The composite, insulated, structuralpanel of claim 13, wherein said sheathing material comprises concrete.17. The composite, insulated, structural panel of claim 16, wherein saidsheathing material comprises foamed concrete.
 18. The composite,insulated, structural panel of claim 13, wherein said sheathing materialcomprises a plurality of shingles.
 19. The composite, insulated,structural panel of claim 13, wherein said sheathing material comprisesfiber reinforced polymer.
 20. The composite, insulated, structural panelof claim 13, wherein said sheathing material comprises fiberglassreinforced polymer.
 21. The composite, insulated, structural panel ofclaim 1, wherein said foam core comprises: a plurality of closed cells;and a chlorofluorocarbon gas disposed in each of said plurality ofclosed cells.
 22. The composite, insulated, structural panel of claim15, wherein said foam comprises a closed cell polyurethane foam.
 23. Thecomposite, insulated, structural panel of claim 15, wherein said foamcomprises a closed cell polyisocyanaurate foam.
 24. The composite,insulated, structural panel of claim 15, wherein said foam comprises aclosed cell polystyrene foam.
 25. The composite, insulated, structuralpanel of claim 15, wherein said foam comprises a closed cell neoprenefoam.
 26. The composite, insulated, structural panel of claim 15,wherein said foam comprises a closed cell polyethylene foam.
 27. Acomposite structural beam, comprising: a pair of interleaved brackets; afoam core disposed between said pair of interleaved brackets.
 28. Thecomposite structural beam of claim 27, wherein said foam core comprises:a plurality of closed cells; and a chlorofluorocarbon gas disposed ineach of said plurality of closed cells.
 29. The composite structuralbeam of claim 27, wherein said foam comprises a closed cell polyurethanefoam.
 30. The composite structural beam of claim 27, wherein said foamcomprises a closed cell polyisocyanaurate foam.
 31. The compositestructural beam of claim 27, wherein said foam comprises a closed cellpolystyrene foam.
 32. The composite structural beam of claim 27, whereinsaid foam comprises a closed cell neoprene foam.
 33. The compositestructural beam of claim 22, wherein said foam comprises a closed cellpolyethylene foam.
 34. A composite jamb stud, comprising: a pair ofinterleaved brackets; a foam core disposed between said pair ofinterleaved brackets.
 35. The composite jamb stud of claim 34, whereinsaid foam core comprises: a plurality of closed cells; and achlorofluorocarbon gas disposed in each of said plurality of closedcells.
 36. The composite jamb stud of claim 34, wherein said foamcomprises a closed cell polyurethane foam.
 37. The composite jamb studof claim 34, wherein said foam comprises a closed cell polyisocyanauratefoam.
 38. The composite jamb stud of claim 34, wherein said foamcomprises a closed cell polystyrene foam.
 39. The composite jamb stud ofclaim 34, wherein said foam comprises a closed cell neoprene foam. 40.The composite jamb stud of claim 34, wherein said foam comprises aclosed cell polyethylene foam.